Process for making coherent materials



March 9, 1943. J MacDONALD PROCESS FOR MAKING COHERENT MATERIALS Filed May 16. 1941 5 Sheefs-heet l INVEIUTOR: J/YMES 9. Mac ow/9L0 ATTORNEY March 9, 1943. J. A. M DONALD PROCESS FDR MAKING COHERENT MATERIALS 5 Sheets-Sheet 2 Filed May 16, 1941 ATTORNEY Marh 9, 1943. J. -A. MacDONALD PROCESS FOR MAKING COHERENT MATERIALS Fild May16, 19 11 5 Sheets-Sheet s 98 1 INVENTOR':

t/HMES fl-MfiCDO/VFILD ATTORNEY arch 9, 1943. V J. A. MacDONALD 2,313,082

PROCESS FOR MAKING COHERENT MATERIALS Filed May 16, 1941 5 Sheets-Sheet 4 110 A1 Si /IRA 70 3 INVENTOR: 125 JHMEZS fl- MfiC0aV/940 A TTORNE Y I March 9, 1943. J. A. MacDONALD 2,313,082

PROCEQS FOR MAKING COHEREN'I' MATERIALS Filed May 16, 1941 5 Sheets-Sheet 5 ATTORNEY Patented Mar. 9, 1943 PROCESS FOR MAK]NG COHERENT MATERIALS James A. MacDonald, Glendale, Galifi, assignor to John U. Birnie, Los Angeles, Calif.

Application May 16, 1941, Serial No. 393,793

8 Claims.

This invention relates to materials embodying a mass of solid or semi-solid particles secured together by binding agents, which can attach the particles to any desired surface, and to processes for making such materials.

Heretofore, dry or solid particles have been premixed with a suitable liquid binder, this mixture then being ejected or sprayed on a surface to be treated or covered. Such pre-mixing possesses many inherent disadvantages, including the lack of control of the consistency of the dry and liquid mixture being ejected from the spray nozzle, which is caused by variations in the proportions of the respective materials entering the nozzle. This non-uniformity in the feeding has required constant adjustments of the controls for the binder and dry'particles in an attempt to maintain the uniformity of the sprayed mixture leaving the nozzle. The rapidity with which the proportions vary makes it almost impossible to accomplish effective coordinated adjustments of the control'members, with the result that the finished product sprayed on the surface to be treated is improperly and non-uniformly mixed.

It is an'object of the invention toovercom'e the above disadvantages by a process in which 9.0- curate controlling and gauging of the proportionate amounts of the various materials sprayed on the surface to be treated is obtained, and in which discharging of the particles and their binder is performed in such manner as to produce a uniformly mixed coating of the sprayed materials on the surface to which they are applied.

In its general aspects, the coherent material formed by my process consists of a generally unifcrmly deposited mass of dry or solid particles held together and on a suitable surface by a binder, such as latex or other flexible or elastic substance. The particles may consist of cork, expanded mica, asbestos, sawdust, leather waste, or any other material that is suitable for the intended purpose, but it is preferred to employ cork particles in view of their relative lightness; I prefer to use latex (including its curingagents) as a binder since the mass of granulated cork particles may be elastically secured thereby to each other and to the surface to which this mixture of material may be applied.

The relative proportions of the generally uniform mixture of latex and cork granules or particles are such that the latex does not cover the entire surface area of each granule, but forms a pervious coating thereon. In addition, the spaces between these granules are not completely filled with the latex binder, the latter being so arranged as to bind the particles together, but still leaving spaces or interstices therebetween through which sound waves 'or fluids can pass. Thus, due to the porous and elastic nature of the mixture, sound waves may pass through the intersticesbetween the corkparticles and the porous, uncoated areas of each particle itself, creating effective sound absorption and dampening. By controlling the proportions of latex and cork granules, the mesh of the granules utilized, and the thickness of this mixture on the surface to be treated, the sound absorption and dampening effectiveness can be varied. Usually, it is desirable to so arrange the mass as to absorb the sound waves in the audible range of frequencies.

Due to the difficulties attending the pre-mixing of the cork granules and liquid latex, as pointed out above, the present invention contemplates the mixture of the granules and its latex binder primarily at or near the surfac to which this mass is to be applied. The latex and cork particles are sprayed on the surface in separate, convergent streams which intersect at or 'near the surface to effect an intimate and uniform mixing of the latex and cork just prior to their deposition on the surface. Because of the ejection of the cork particles and "the liquid binder from separate points, their relative proportions may be easily'con'trolle'd and maintained constant, enabling the production of a uniform product possessing many desirable characteristics, in-

cluding friction and insulating properties, and

the'acoustic qualities previously referred to.

'acter indicated maybe understood with particularity by referring to the drawings comprising part of the present specification, in which one form of apparatus is disclosed for performing the process by applying a uniform mixture of dry or semi-solid particles and a liquid binder on sheets of fabric material.

In the drawings: Fig. 1 is a generally side 'elevational view of the apparatus; I

Fig. 2 is a longitudinal section of the spraying portion of the apparatus; 7

Fig. 3 is a section taken along the line 33 of Fig. 2; v I l Fig. 4 is a section taken along the line 44 of Fig. 3; v

Fig. 5 is a side elevation of a set .of cork and latex guns, and the manner of adjustably supporting them; V

Fig. 6 is a View of a cork gun taken along the line 6-5 of Fig. 5;

Fig. 7 is an end view of the cork gun taken in the direction of the arrow 1 of Fig. 6

Fig. 8 is a longitudinal section of the latex Fig. 9 is a diagrammatic view of the spray pat terns formed by the substances ejected from the cork and latex spray guns; and g p 1 Fig. 10 is a diagrammatic representation of the flow control system for the various spray guns of the apparatus. 7 7 y,

As disclosed in the drawings, the machine or gun,

apparatus includes a main supporting frame l9 having a :bed H along which a conveyor belt l2 moves for carrying the fabric material 13 with it. This belt I2 is driven at any suitable speed by a driving roll or pulley l4, the slack side of the belt being supported by the idler pulleys I5 placed at spaced distances along the frame. The belt passes over a return roller pulley l6, which is rotatably mounted in a movable frame or carriage I! provided with grooved wheels I8 for riding on tracks l9 at the sides of the machine. A device is provided for holding the belt in proper tension by tending to move the driven pulley carriage ll away from the driving pulley I4.

The tensioning device consists of a cable 29 attached to each side of the carriage l1, each cable extending generally horizontally from the carriage and passing over an idler pulley 2| suitably supported in bearings near the lower end of a vertical frame 22, from where the cable 20 extends upwardly in a vertical direction to a second idler pulley 23 rotatably mounted at the upper end of the frame 22. The cable passes over and depends from this pulley, and has a weight 24 attached to its end to provide the necessary cable tension tending to produce horizontal movement of the carriage l1 and separation between the driving and driven conveyor rolls I 4, Hi, to maintain suitable tension in the conveyor belt [2.

Fabric material I3 is suitably supported in roll form for passage into a spraying booth 25 and onto a platen 26 of the apparatus, where a mixture of cork granules and latex are applied to its-upper surface. From the spraying booth 25, the fabric material with the coating applied ably enclosed in a cabinet so provided with ventailating slots 3|, throughwhich any vapors released during the vulcanizing process can pass.

Following vulcanization, the conveyor belt l2 continuously feeds the material up an inclined ramp 32 for passage between a pair of calender rolls 33, which press the material to reduce its thickness and consolidate the mass to' a predetermined extent. After leaving the calender rolls, the coated fabric is conveyed between a pair of final pressure rolls 34, which determine the final thickness of the coated fabric material. The pressure of these rolls 34 may be adjusted to any desired degree. The finished material is then wound up in roll form on a pair of spaced, rotatable idler rolls 35 extending across the frame of the machine.

The calender rolls 33, pressure rolls 34, idler rolls 35 and driving pulley 14 are rotated by any suitable driving means (not shown), their peripheral speeds preferably being synchronized. The speed of the driving pulley, and also of the other roller members, can be varied, in order to vary the speed at which the fabric I3 is being conveyed or fed through the apparatus. This speed will be chosen so as to determine the thickness of the coating applied to the fabric and the time during which the vulcanization or drying operation takes placeunder the infrared lamps. If desired, additional infra-red lamps 36 may be provided along the machine for further heating action upon the material.

If a priming coat of latex is to be provided on the surface of the fabric prior to application of the cork and latex mixture, the fabric is first caused to enter and proceed through a priming cabinet 3'! where spray guns 38 will eject latex on its surface, this material then passing under infra-red lamps 39 for drying and vulcanization before entering the spraying cabinet or booth 25 where the mixture of cork and latex is applied. The priming coat is preferably only dried sufficiently to remain in a slightlytacky state to receive the mixture of cork and latex to better advantage. Any fumes or vapors from the spray booths 25, 3'! Will be carried off through the exhaust pipes 40, 4|.

The cork particles and liquid latex are caused to mix at or immediately above the surface of the fabric l3 by being'ejected from separate guns 42, 43 whose sprays 44, 45 begin to inter sect at a point or line 46 which is a certain distance above the fabric, there being substantially complete intersection or coincidence of the sprays at the fabric. These sprays are of generally conical form, diverging from the gun outlets, the latex spray being in atomized form for complete enveloping of each particle in the cork stream to form a coating therearound which becomes pervious upon drying, due to the evaporation of water and other liquids. As was stated above, the latex provides an elastic binder between each particle, and also between the particles and the fabric material.

The cork particles of the desired mesh are contained in a hopper 41 in which agitator elements 48 are rotatable by a suitable driving device 49 to prevent the particles from coning or packing. The particles pass through a screen 50 in the hopper and into an aggregate chamber 5| into which projects an air nozzle 52 for blowing or forcing the cork through a flexible hose or tubing 53 into the inlet 54 of the cork gun 42. From this inlet 54, the cork particles pass into a nozzle 55 whose front 56 and back 51 converge in the direction of the nozzle mouth 58, While its sides 59 diverge towards this mouth, which is of restricted shape and of arcuate form, the width of the mouth gradually increasing fromits center line to the sides 59,'for the purpose of obtaining a uniform discharge of particles and distribution on the fabric surface. This uniformity is assisted by angling the nozzle 55 to the axis of the inlet 54, causing impingement of the particles on the back portion 57 as they leave the inlet to be deflected thereby in fan-like fashion across the entire width of the nozzle. The width of the spray leaving the nozzle is also controlled and made uniform by the arcuate shape 58 at its outlet end.

Th sides 59 of the nozzle are split, being formed with overlapping inturned edges 60 to provide for variations in the mouth opening, while preventing leakage or passage of the cork particles through the side faces. This adjustment or variation is accomplished by welding or otherwise securing bands 6| to the front and back of the nozzle adjacent its mouth 58, and by providing a pair of adjusting screws 62 extending through the bands. The distance between the ends of the front 56 and back 51 of the nozzle is determined by a lock nut 63 threaded on each screw and adapted to engage one of the bands. By loosening the lock nuts and turning each screw 62 to the desired extent, the thickness of the mouth 58 of the nozzle can be altered to control the amount of material issuing from th nozzle and its conical spray pattern.

The latex spray gun 43 (see Fig. 8) is of a known design, being adapted to eject a generally flat conical spray. This gun consists of a body 64 having a fluid inlet 65 through which liquid latex may pass into a discharge passage 66 for ejection through the nozzle 61. Such ejection is determined by a fluid needle 68 adapted to close the nozzle 6! and extending through the passage 66 and through suitable packings 69 and packing nuts I into a cylinder 1 I, where it is attached to a piston I2. This piston carries a suitable cupshaped packing I3 for slidable engagement with the cylinder wall. Air may enter through an inlet I4 in the body for passage into the cylinder 1 I, acting on the piston I2 to move it toward the cylinder head I5, and in so doing causing the fluid needle 68 to be retracted within the passage to permit the latex to discharge through the nozzle 67. Such movement of the piston by the action of air under pressure takes place against the force exerted by a piston spring I6 confined between the piston and cylinder head, this spring returning the needle to closed position when the air pressure is released. The extent of opening of the needle 68 when air under pressure is admitted to the cylinder is determined by an adjusting screw '7! at the head end of the cylinder.

Air at a regulated and predetermined pressure enters the air inlet I8 of the gun body, passing through an air adjustment valve I9, which may further control the air pressure and the quantity flowing into an air passage exiting into the passag 66 and into an air cap 8| forming an annular chamber with the fluid nozzle 61. Air will pass from this chamber through discharge holes 02 adjacent the fluid nozzle exit, striking the latex ejected through this nozzle and atomizing it for intimate mixture with the cork spray from the cork gun 42. The spray pattern can be controlled by means of the spreader adjuster 83 and the retainer nut 84 holding the air cap 8! in place. Both the cork guns 42 and liquid latex guns 43 are adjustably mounted to permit alteration in the angles at which they are disposed with respect to one another and with respect to the fabric material I3, and also the distances by which they are separated from one another and from the material. Fig. 5), the cork gun inlet pipe 54 is mounted in a clamping collar 85 secured to a swivel rod 86 extending from a swivel 8! adapted to pivot on a clamping bolt or pin 8-8 secured to a shaft 89 slidable within a clamp adjustably fixed to a supporting rod or bar 9|. It is apparent that loosening of the swivel bolt 89 will permit the angle of discharge of the cork gun to be varied, while loosening of the clamp 90 will permit the swivel shaft 89 to be adjusted for the purpose of altering the vertical distance of the cork gun from the fabric. Moreover, the clamp 90 can be shifted on the supporting bar 9| to alter the distance between the cork and latex guns.

The latex gun 43 is also adjustably mounted in a similar manner by being clamped to a rod 65 extending from a. swivel 8! which can pivot about a suitable clamping bolt or pin 88 fixed to a shaft 99 slidable within a clamp 90 adjustably mounted on the supporting bar 9|. Due to this arrangement, the latex gun 43 may alsopivot about the pin 88 to change its angle of discharge with respect to the material, and its vertical distance thereabove may also be altered by adjusting the shaft 89 in the clamp 90, Similarly, its

In the present instance (see clamp 90 is shiftable on thesupporting bar 9I to alter its distance from the cork gun 42.

If the width of the fabric material is substan tial, a plurality of sets of cork and latex guns should be employed. Each set is mounted on a supporting rod or bar 9I extending lengthwise of the machine, the bars being secured to supporting cross members 92 attached to side plates 93, each of which is fixed to a movable side head 94 clamped by bolts 95 to a stationary head 96 forming part of a carriage 91 adapted to be shifted longitudinally within the spray booth 25 on wheels 98 rotatably carried by its depending legs 99. By longitudinally shifting the spray carriage 91, all of the guns are correspondingly shifted. Furthermore, by vertically adjusting the movable heads 94 with respect to the stationary heads 96, all of the nozzles will be moved vertically to the same extent.

The simultaneous vertical adjustment of all of the spray guns can be accomplished in any suitable manner. In the present instance (see Figs. 2, 3 and 4) the fastening bolts 95 extend through vertical guide slots I00 in the stationary head members, each of the movable head members 94 being shiftable by a chain IOI having one end attached to the movable head 94, as by means of a bolt I02, the chain passing over a sprocket I03 fastened on an operating shaft I04 extending across the machine, and having its other end fastened to the stationary head 96, as by means of a second bolt I05. A hand wheel I06 is secured to the operating shaft I04 externally of the spray booth 25 for the purpose of rotating the shaft and sprockets I03 to elevate or lower the movable head 94 with respect-to the stationary head 96. Whenever such vertical adjustment is to occur, the fastening bolts 95 are loosened, the hand wheel I06 turned in the proper direction to raise or lower the movable heads by the desired extent, and the bolts 95 then tightened to clamp the movable heads to the stationary heads. It will be noted that the operating shaft I04 extends through a horizontal slot I01 in the spray booth to permit movement of the spray carriage 9'I longitudinally of the apparatus.

Fig, 10 discloses a flow diagram of the system for feeding air, latex, and cork particles to the various spray guns. Air is supplied by an air compressor I08, passing therefrom through a suitable line I69 into an air separator IIO, where condensate may be eliminated. From this separator, air flows through a line III and through a control valve I I2 into the upper end of a pressure tank H3 containing the liquid latex. This latex is forced under pressure from the tank through a suitable control valve I I4 into a header I I5, from where a flexible hose or line'65a leads to the fluid inlet 65 of each latex spray gun 43.

Another air line I I6 continues from the air separator, branching into a header III for supplying air to the cylinders II and pistons I2 which control the latex needles 68 in the various spray guns. The passage of air into these cylinders is determined by a control valve I I8 at the inlet end of the needle header" III, which not only functions to permit or prevent passage of air into this header and through the flexible hose H9 connected to the air inlets I4 of the latex guns. but also is capable of adjustment to allow air to bleed back from these guns through their flexible hose H9 and main header III to the atmos phere, for the purpose of allowing the various return springs I6 to move the needles 69 to closed positions.

An air line I continues from the line II6 to a second air separator I2I, from where the air passes through a pressure regulator I22 into a second air header I 23, to which are connected flexible tube I24 attached to the air inlets 18 of the latex guns, through which regulated air is supplied for atomizing the liquid latex.

Still another air line I25 is connected to a header I26 for supplying air to the chambers 5I leading from the cork hopper 41. This air passes through an air pressure regulator I21 into the header I26, from where it is fed through separate lines I28, each of which has a control valve I29 therin, for ejection from the air nozzles 52 extending. into the cork particle chambers 5|. The positions of these nozzles 52 inwardly of the chamber can be varied to alter the quantity of aggregate or particles forced through the flexible tubes 53 and the cork guns 42.

If fogging or sealing latex guns I30 are employed in the fogging cabinet 21, another header I 3| may extend from the latex pressure tank, with individual pipes I32 running to each gun I30. Similarly, the regulated air and needle headers I23, II'I may be extended to permit the running of separate lines I33, I34 to their regulated air inlets I8 and cylinder inlets I4, respectively,

By virtue of the control system just described, it is possible to simultaneouslycontrol all of the guns. The air regulators I22, I21 may be adjusted for determining the air pressures to be supplied to the cork nozzles 42 and the atomizing inlets I8 of the latex guns 43. The single control and bleedervalve I I8 for the needleheader II'I enables simultaneous opening and closing of theneedles 68 to occur, to produce a corresponding simultaneous spraying or stoppage of liquid latex from the guns.

The cork and latex guns are angled in the direction of travel of the fabric material, the latex gun 43 of each set being positioned ahead of the cork gun 42. Since the sprays 45, 44 from these two guns are to converge, the angle at which the cork gun is adjusted is greater than that of the latex gun, the speed of impact of the cork on the fabric material I3 being determined by the air pressure in the cork nozzle 55. This speed of travel is preferably such as to cause the cork particles to impinge into the latex stream 45 and prevent the cork from dropping prematurely to any substantial extent before meeting the latex stream. It ispreferred that the leading portion 450. of the latex spray impinges on the fabric slightly ahead of the leading portion 44a of the l cork spray to provide added adhesion of the cork particles to the fabric and also to insure thorough covering of any cork particles that might be deflected from the main stream or from the surface of the fabric. By causing the streams to intersect, a thorough commingling of the cork particles and liquid latex is obtained, to insure the deposition of a uniform mixture on the fabric.

When more than one set of cork and latex guns is employed, they should not only be separated from one another by spaced distances across the width of the fabric, but they should also be staggered, as by arranging one ahead of another, so that the streams issuing from one set do not interfere with the sprays from any other set, resulting in the deposition of a uniform coating and thickness over the entire surface of the fabric material. Fig. 9 illustrates in a general way the spray patterns from the cork guns 42 and the latex guns 43.

Although particular reference has been made to the discharge of latex from the guns, actually a mixture of latex, curing agents, and accelerating agents are contained in the pressure tank II 3 for discharge through the liquid guns 43. The curing agents may be sulphur and zinc oxide, while the accelerators are preferably those which will provide a rapid vulcanization of the latex, since only a comparatively short period of time is available as the material passes under the infrared lamps 29 in which to effect curing of the latex. Among the accelerators that may be employed are hexamethylenetetramine, butyl zimate, and mercaptobenzothiazole. One particular mixture that may be discharged from the latex guns includes parts by weight of latex, 5 parts of zinc oxide, 1.75 parts sulphur, and 0.25 part accelerator. This mixture will be cured in about four minutes at a temperature of degrees centigrade supplied by the infra-red lamps.

The point or line 45 at which the latex and cork sprays 44, 45 begin to intersect may be varied depending upon the concentration of the latex and the particle size of the cork, which can be from 10 to 26 mesh, although larger and smaller particle sizes may be utilized, depending upon the article or surface that is desired. One example of proportions of cork and latex which might be employed is as follows:

Cork granules pounds 50 Latex gallons 16 These proportions may be varied, however, without departing from the process, depending upon the characteristics desired in the finished material.

The apparatus described herein is claimed in my application entitled Apparatus for producing coherent-materials, filed May 16, 1941, and bearing Serial No. 393,792. I

From the foregoing description of the apparatus, it is apparent that a uniform mixture of cork particles and latex can be sprayed on any desired surface, including sheets of fabric material. This material, which may bemuslin or burlap, provides a base on which the separate, convergent and intersecting streams of latex and cork particles are sprayed as the fabric travels continuously in the same direction past the spraying station. By regulating the speed at which the conveyor I2 carries the material I3 past the spraying station 25, and the quantities of cork particles and liquid latex emanating from their respective nozzles, the thickness and characteristics of the mass deposited on the fabric may be varied to suit different conditions of use. After passing the spraying station, the fabric with the cork granules and latex applied thereto is heated, as by the infra-red lamps 29, for. the purpose of vulcanizing the latex to effect its permanent adhesion to the cork particles and to the fabric. The fabric with the cured mass thereon is compressed by the calender and pressure rolls 33, 34 to the required thickness, which can be about e or greater, depending on the service for which the material is intended, and the material is then rolled up for storage, shipment or use.

The coated fabric material has several beneficial uses. For example, it can be applied in a manner of wallpaper on a hard, non-absorptive surface, such as a plastered wall or the like, and in this use its sound absorptive and dampening qualities are appreciable. When used for this purpose, it is preferred that the quantity of latex employed be insufficient to seal the fabric, the

surface of each cork particle, or to close the interstices between the particles. This is a very inexpensive method of applying acoustic material to walls, as can be well appreciated. Th sound absorptive properties of the material also permit its use to good advantage as pads under various types of oflice equipment, such as typewriters, calculating machines, business machines, etc. By providing such pads between the machine and a sound reflective supporting surface, an appreciable amount of the audible sound waves are dampened.

When used for sound absorption purposes, it is preferred that the quantity of latex employed be such as to be incapable of sealing not only the entire surface of each cork particle and the interstices" therebetween, but also the fabric material itself on which the particles or granules are deposited. By virtue of this construction, sound waves not absorbed or dampened in the interstices or by the cork and latex substances may be absorbed or dampened in the spaces defined by the weft and warp of the fabric material.

A further use to which the fabric material may be put is as a membrane in front of an absorptive filler, such as rock wool or the like. In this use, its possesses considerable value since it is formsustaining and will give an even, firm surface to such fillers. When used for this purpose, the particle mass on the fabric may be made thinner than when the material is applied to a nonabsorptive wall, since the sound waves can penetrate the membrane and be absorbed in the rock wool, although, of course, the sound will also be absorbed somewhat in its passage through the interstices between the cork particles. The use of materials such as latex as a binder also makes the membrane somewhat elastic or pliable so that sound waves in the lower frequencies are also dampened by this binder.

A further use of the coated fabric material is as a friction pad under rugs or other articles, to prevent their movement and maintain them in a fixed position. In this connection, the sealing coat and the extent of drying can be controlled to provide a slightly sticky or tacky consistency to the fabric to improve its non-slip qualities.

From the foregoing, it is apparent that I have provided an improved material and process for making the same, the material having a wide range of uses, including that of acoustical correction and inherent sound absorption and dampening throughout the audible range of frequencies. The latex binder forms a tenuous film between the cork particles providing the elastic properties referred to above and assisting in the sound absorptive qualities of the material.

While I have described a preferred form of my material, and a preferred process of making the same, it is to be understood that various changes in both thereof may be made by those skilled in the art without departing from the spirit of the invention as defined in the appended claims.

Having thus described my invention, what I claim and desire to secure by Letters Patent is:

l. A process for producing coherent materials, including spraying convergent streams of a mass of granulated cork and liquid latex from spaced points, whereby said streams intersect to effect co-mingling of said cork granules and latex to produce a uniform, adherent mixture therebetween.

2. A process for producing coherent materials, including spraying convergent streams of a mass of granulated cork and atomized liquid latex from spaced points, whereby said streams intersect to effect uniform co-mingling of said cork granules and latex to produce a latex coating on the surface of each cork granule and a tenuous binder therebetween.

3. A process of the character described, including providing a sheet of material, simultaneously ejecting towards said material from spaced points separate convergent streams of granulated cork and atomized liquid latex which intersect adjacent the surface of said material to effect uniform co-mingling of said cork granules and latex prior to their deposition on surface.

4. A process of the character described, including providing a sheet of material and placing the same in motion in a continuous direction, simultaneously spraying towards said material from spaced points separate convergent streams of a mass of granulated cork and liquid latex which intersect adjacent the surface of said material to effect uniform co-mingling of said granules and latex prior to their deposition on said surface, and then vulcanizing the latex.

5. A process of the character described, including providing a sheet of material and placing the same in motion in a continuous direction, simul taneously spraying towards said material a divergent stream of a mass of granulated cork and a divergent stream of liquid latex, said streams being angled in the direction of motion of said sheet and converging for intersection adjacent the surface of said material to effect uniform comingling of said granules and latex prior to their deposition on said surface, vulcanizing the latex, and then compacting the mass deposited on said sheet to a desired thickness.

6. A process of the character described, including providing a sheet of material and placing the same in motion in a continuous direction, spraying a priming coat of latex on the surface of said material, then simultaneously spraying towards said material a divergent stream of a mass of granulated cork and a divergent stream of liquid latex, said streams being angled in the direction of motion of said sheet and converging for intersection adjacent its surface to effect a uniform mixture of said granules and latex prior to their deposition on said surface, and then vulcanizing the latex.

'7. A process of the character described, including providing a sheet of material and placing the same in motion in a continuous direction, simultaneously spraying towards said material a stream of a mass of granulated cork and a stream of liquid latex, said streams being angled in the direction of motion of said sheet and converging for intersection adjacent its surface to effect a uniform mixture of said granules and latex prior to their deposition on said surface, depositing a covering coat of latex on said mixture, and then vulcanizing the latex.

8. A process of the character described, including providing a sheet of fabric and placing the same in motion in a continuous direction, depositing a priming coat of latex on the surface of said fabric, then simultaneously ejecting towards said surface from spaced points separate convergent streams of a, mass of granulated cork and liquid latex which intersect adjacent the surface of said material to effect a uniform mixture of said granules and latex prior to their deposition on said surface, and then depositing a covering coat of latex on said mixture.

JAMES A. MACDONALD. 

